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Abstract

This paper analyses the possibility of applying thermal barrier coatings (TBCs) onto a substrate made of the AlSi7Mg alloy, intended for, among other things, internal combustion engine components. Engine components made of aluminum-silicon alloys, especially pistons and valve heads, are exposed to high temperature, pressure and thermal shock resulting from the combustion of the fuel-air mixture. These factors cause degradation of these components and can lead to damage. To minimize the risk of damage to engine components caused by heat stress, one way is to apply TBCs. Applying TBCs coatings to engine components improves their durability, increases power output and reduces fuel consumption. The research scope includes the application of an Al2O3-TiO3 coating via the APS (Air Plasma Spraying or Atmospheric Plasma Spraying) method onto a substrate of the AlSi7Mg alloy, analysis of the microstructure and chemical composition of the substrate and coating material, and assessment of the quality of the coating's bond with the AlSi7Mg alloy substrate using the scratch test method.
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Bibliography

[1] Chen, C., Sun, C., Wang, W., Qi, M., Han, W., Li, Y., Liu, X., Yang, F., Gou, L. & Guo, Z. (2022). Microstructure and mechanical properties of in-situ TiB2/AlSi7Mg composite via powder metallurgy and hot extrusion. Journal of Materials Research and Technology. 19, 1282-1292. https://doi.org/10.1016/j.jmrt.2022.05.117.
[2] Rambabu, P., Eswara Prasad, N., Kutumbarao, V.V., Wanhill, R.J.H. (2017). Aluminium Alloys for Aerospace Applications. In: Prasad, N., Wanhill, R. (eds) Aerospace Materials and Material Technologies . Indian Institute of Metals Series. Springer, Singapore. https://doi.org/10.1007/978-981-10-2134-3_2.
[3] Sonsino, C.M. & Franz, R. (2017). Multiaxial fatigue assessment for automotive safety components of cast aluminium EN AC-42000 T6 (G-AlSi7Mg0. 3 T6) under constant and variable amplitude loading. International Journal of Fatigue. 100(2), 489-501. https://doi.org/10.1016/j.ijfatigue.2016.10.027.
[4] Dolata, A.J., Dyzia, M., Jaworska, L. & Putyra, P. (2016). Cast hybrid composites designated for air compressor pistons. Archives of Metallurgy and Materials. 61(2A), 705-708. http://dx.doi.org/10.1515%2Famm-2016-0120.
[5] Siadkowska, K. & Czyż, Z. (2019). Selecting a material for an aircraft diesel engine block. Combustion Engines. 58(3), 4-8. DOI: http://dx.doi.org/10.19206/CE-2019-301.
[6] Floweday, G., Petrov, S., Tait, R.B. & Press, J. (2011). Thermo-mechanical fatigue damage and failure of modern high performance diesel pistons. Engineering Failure Analysis. 18(7), 1664-1674. https://doi.org/10.1016/j.engfailanal.2011.02.002.
[7] Azadi, M., Mafi, A., Roozban, M. & Moghaddam, F. (2012). Failure analysis of a cracked gasoline engine cylinder head. Journal of Failure Analysis and Prevention. 12, 286-294. https://doi.org/10.1007/s11668-012-9560-6.
[8] Krstic, B., Rasuo, B., Trifkovic, D., Radisavljevic, I., Rajic, Z. & Dinulovic, M. (2013). Failure analysis of an aircraft engine cylinder head. Engineering Failure Analysis. 32, 1-15. https://doi.org/10.1016/j.engfailanal.2013.03.004.
[9] Jing, G.X., Zhang, M.X., Qu, S., Pang, J.C., Fu, C.M., Dong, C., Li, S. X., Xu, C.G. & Zhang, Z.F. (2018). Investigation into diesel engine cylinder head failure. Engineering Failure Analysis. 90, 36-46. https://doi.org/10.1016/j.engfailanal.2018.03.008.
[10] Sharma, P., Dwivedi, V.K. & Kumar, D. (2021). A review on thermal barrier coatings (TBC) usage and effect on internal combustion engine. Advances in Fluid and Thermal Engineering: Select Proceedings of FLAME 2020, 77-85. https://doi.org/10.1007/978-981-16-0159-0_8.
[11] Dhomne, S. & Mahalle, A.M. (2019). Thermal barrier coating materials for SI engine. Journal of materials research and technology. 8(1), 1532-1537. https://doi.org/10.1016 /j.jmrt.2018.08.002.
[12] Gürbüz, H. (2022). Experimental investigation of the effects of ethanol‐diesel mixture on the performance and emissions of the thermal barrier coated diesel engine. Environmental Progress & Sustainable Energy. 41(1), e13718. https://doi.org/10.1002/ep.13718.

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Authors and Affiliations

Marek Mróz
ORCID: ORCID
Patryk Rąb
ORCID: ORCID

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Abstract

This paper presents the possibility of improving the scratch resistance of the AZ91 magnesium alloy by applying a WCCoCr coating using the Air Plasma Spraying (APS) method. The coating thickness ranged from 140 to 160 m. Microstructural studies of the AZ91 magnesium alloy were performed. The chemical composition of the WCCoCr powder was investigated. The quality of the bond at the substrate–coating interface was assessed and a microanalysis of the chemical composition of the coating was conducted. The scratch resistance of the AZ91 alloy and the WCCoCr coating was determined. The scratch resistance of the WCCoCr powder-based coating is much higher than the AZ91 alloy, as confirmed by scratch geometry measurements. The scratch width in the coating was almost three times smaller compared to the scratch in the substrate. Observations of the substrate–coating interface in the scratch area indicate no discontinuities. The absence of microcracks and delamination at the transition of the scratch from the substrate to the coating indicates good adhesion. On the basis of the study, it was found that there was great potential to use the WCCoCr powder coating to improve the abrasion resistance of castings made from the AZ91 alloy.
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Bibliography

[1] Wanhill, R.J.H. (2017). Carbon fibre polymer matrix structural composites. Aerospace Materials and Material Technologies. 1, 309-341. https://doi.org/10.1007/978-981-10-2134-3_14.
[2] Dziadoń, A. & Mola, R. (2013). Magnesium – directions of shaping mechanical properties. Obróbka plastyczna Metali. XXIV(4). (in Polish).
[3] Mordike, B.L. & Ebert, T. (2001). Magnesium: Properties – application – potential. Materials Science and Engineering. 302(1), 37-45. DOI: 10.1016/S0921-5093(00)01351-4.
[4] Wang, G.G. & Weiler, J.P. (2023). Recent developments in high pressure die-cast magnesium alloys for automotive and future applications. Journal of Magnesium and Alloys. 11(1), 78 87. DOI: doi.org/10.1016/j.jma.2022.10.001.
[5] Liu, B., Yang, J., Zhang, X., Yang, Q., Zhang, J., Li, X. (2022). Development and application of magnesium alloy parts for automotive OEMs: A review. Journal of Magnesium and Alloys. 11(1), 15-47. DOI: 10.1016/j.jma.2022.12.015.
[6] Janik, B. (2011). Application of magnesium alloys in aviation. Prace Instytutu Lotnictwa. 57(221), 102-108. (in Polish).
[7] Prasad, S.V.S., Prasad, S.B., Verma, K., Mishra, R.K., Kumar, V. & Singh, S. (2021). The role and significance of Magnesium in modern day research – A review. Journal of Magnesium and alloys. 10(1), 1-61. DOI: 10.1016/j.jma.2021.05.012.
[8] Blawert, C., Hort, N. & Kainer, K.U. (2004). Automotive applications of magnesium and its alloys. Transaction of the Indian Institute of Metals. 57(4), 397-408.
[9] Chen, H. & Alpas A.T. (2000). Sliding wear map for the magnesium alloy Mg-9Al-0.9Zn (AZ91). Wear. 246(1-2), 106-116. DOI: 10.1016/S0043-1648(00)00495-6.
[10] Walczak, M., Caban, J. & Pliżga, P. (2015). Tribological characteristic of magnesium alloys used in means of transport. TTS Technika Transportu Szynowego. 22(12), 1614-1617.
[11] Parco, M., Zhao, L., Zwick, J., Bobzin, K. & Lugscheider, E. (2007). Investigation of particle flattening behaviour and bonding mechanisms of APS sprayed coatings on magnesium alloys. Surface and Coating Technology. 201(14), 6290-6296. DOI: 10.1016/j.surfcoat.2006.11.034.
[12] Morelli, S., Rombol`a, G., Bolelli, G., Lopresti, M., Puddu, P, Boccaleri, E., Seralessandri, L., Palin, L., Testa, V., Milanesio, M. & Lusvarghi, L. (2022). Hard ultralight systems by thermal spray deposition of WC-CoCr onto AZ31 magnesium alloy. Surface and Coating Technology. 451, 129056 1-26. DOI.org/10.1016/j.surfcoat.2022.129056.
[13] Gray, J.E. & Luan, B. (2002). Protective coatings on magnesium and its alloys – a critical review. Journal of Allys and Compounds. 336(1-2), 88-113. DOI: 10.1016/S0925 8388(01)01899-0.
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Authors and Affiliations

Marek Mróz
1
ORCID: ORCID
Sylwia Olszewska
1
ORCID: ORCID
Patryk Rąb
1
ORCID: ORCID

  1. Rzeszow University of Technology, Poland

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